Method and mold for applying stucco on walls to represent stone



June 16, 1942. D D. s. FRALlcK 2,286,531k

METHOD AND MOLD FOR APPLYING STUCCO ON WALLS TO REPRESENT STONE 15j/151017159 zlllllo June 16, 1942. D. s. FRALICK METHOD AND MOLD FOR APPLYING STUCGO ON WALLS TO REPRESENT STONE 3 Sheets-Sheet 2 Filed Feb. l0, 1941 magnus Sfrimk June 16. 1942. D. s. FRALlcK 2,236,531

METHOD AND MOLD FOR APPLYING STUCCO ON WALLS T0 REPRESENT STONE 3 Sheets-Sheet 3 Filed Feb. 10, 1941 (D puni" G5 'llll I Q www K c mit 3d d r t.- m I W/ .mn S m L 6 \o lo0 1 u A HHIH |L|r| nuulunnlllnlurl. H.. 0 S..- M MH 6 .f. W/M m m ...Tw e V 1 a .m S. Q 6. m Vzw u M .1M .mw w wg Patented June 16, 1942 UruriszoA srArr-:sUPATr-Nr OFFICEA METHOD AND MOLD FOR APPLYING STUCCO N WALLS TO REPBESENT STONEy Douglas S. Fralick, Milwaukee, Wis. Application February 10, 1941, Serial No. 378,195 9 Claims. (Cl. 18-59) The object of my invention is to provide an improved and effective means of applying-cast stone directly on walls from molds thereby eliminating the time, labor, and expense required in the manufacture and setting of pre-cast stone.

It is also an object of my invention to utilize a thin oiled, waxed, or like paper to eliminate adhering of fresh material to the mold.

Itis a further object of my invention to pro-A vide a mold that can be applied to straight walls, slightly curved walls or corners of walls by means of hinged sections, and to provide a mold that is easily handled. l

It is also an object of my invention to provide a process which allows the workman to apply a surface finish of light colorwith the use of only a very small fraction of the more expensive colored stucco, using, for the most part, stucco base coater made with the ordinary mason sand.

I attain these and other objects of my invention by the mechanism illustrated in the accompanying drawings, in which- Figure l is atop plan view of my mold;

Fig. 2 is a side elevation of same;

Y Fig. 3 is a top plan view of a modification of of the invention;

Fig. 4 is a longitudinal section on line 4-4 of Fig. 3, a portion of the device shown in elevation;

Fig. 5 is a side elevation illustrating the device as used on a fiat surface; and

Fig. 6 is a view partly in side elevation and partly in section of the device withA the hinge pin removed for molding a corner section of the building.

Like characters of reference indicate like parts in each of the several views.

Referring to the accompanying drawings, I provide a mold which, as a whole, is designated A, comprising like sections 2 and 3, normally in contact at the division line I and held in operative relation by a hinge 4 adjacent the inner edge of the mold, `as shown in Figs. 2, 3, and 4. The hinge 4 is fastened to the Vrespective sections 2 and 3 by the screws 5. The mold sections 2 and 3 are secured together in their normally aligned position by a fastening device 6, which is fastened by a series of screws 1 to the sections 2 and 3 of the mold as shown in Fig. 1. The mold sections have tap holes 8, as shown in Fig. 3 for the screws 1, as shown in Fig. 1. A removable pin 9 completes the fastening device 6. Cast integral with the sections 2 and 3 are posts or supports I0 each of which is provided with a longitudinal rib Il. Handles l2 are secured to the posts by screws yI5 and the handles are anchored to preventv turning by the ribs II which project into corresponding recesses in the ends of theA handles. y l

The formvsections 2 and 3 are provided ywith tap holes I4, as shown in Fig. 3, along the sides and ends to receive thescrews I5, as shown in Fig. 2 by which the sheet metal edge guards I6 and I6' and the rubber fins of mold walls I1 are fastened to the sections 2 and 3. The mold sections 2 and 3 are formed with a stone design I8 forming the face of these members. The body members are also provided with spaced vent holes I9, as shown in Fig. 3. y Mounted on the face of the stone design is a sheet of waxed paper 20, as shown in Fig. 6. The Walls cfa building is designated as 2|, while 22 is the stucco face on which is placed the stone nish 23 to form the ornamental stone design, the sheet of waxed paper 20 being interposed between the stone finish and the stone design of the mold sections 2 and 3, as shown in Fig. 6.

The two handles I2 are mounted in a parallel position so as to act as a rest for the mold, as shown in Fig. 5,' when it is filled and awaiting application, andto aid in exerting pressure on the mold by the operator during application.

The face of the mold is irregular rock-faced to represent or simulate the natural stone to be imitated. The rubber ns or strips which are fastened to the edges of the molds by the edge guards I6 and I6' extend around the entire outer edge of the mold and project from the edge of the face of the mold, as shown in Fig. 4 to hold the paper in place during lling; to allow the mold to be filled to greater capacity; to facilitate the vibrating of the mold against the wall; to a1- low a greater amount of compression of plastic material or stucco in the mold which also causes the rubber to give outward and release excess materiaL'a-nd to form a bead between successive molded sections of the stone face of the wall.

Referring to Fig. 6, it will be noted that the mold sections 2 and 3 have an inner hinge 4 and an outer hinge 6. When the mold sections are aligned, both hinge pins are in place. When it is desired to apply the mold to corner sections of a wall, the pin 9 of the fastening device 6 is withdrawn, thus permitting the sections to pivot or hinge on the inner hinge 4. The metal edge guard holds the rubber fin in place and prevents the rubber from being pushed too far back or out cf line when pressure is exerted against the wall.

The holes I9 are bored through the mold sections 2 and 3 at their thinnest portions to prevent a vacuum when the mold is raised from the wall and to prevent air from being trapped between the face of the mold and the paper, as well as toallow the escape of water in excess of that needed to solidify the powdered, dry stucco.

In carrying out my method of applying plastic material on walls to represent stone, I place a sheet of thin waxed paper in the mold, add colorlng material if desired, fill the mold with wet stucco, then grasping the molds by the handles, place the open face in position against the wall. I then vibrate the mold in all directions which the rubber fins or walls I1 permit. The excess material is then forced out past the rubber fins which give outwardly and release the material. This vibration also releases excess water and gives the imitation stone great density. This vibration also forces the wet stucco to adhere to the previously prepared stucco base. The mold is then removed from the wall, and the waxed paper remains on the imitation stone, having prevented l. In a mold for applying stucco on walls to l represent stone, the combination of a pair of molds having their face formed to represent stone, vent holes through the molds bored at their thinnest portions to prevent the formation of vacuum when the mold is withdrawn from the wall, rubber fins projecting forwardly beyond the operative surface of the molds to a sufcient distance to hold a sheet of waved paper and to also retain a desired amount of stucco finish, sheet metal guards secured to the molds land holding the said rubber ns in place, a hinged connection for the molds, and means for manually operating the molds.

2. In a mold for applying stucco on walls to represent stone, the combination of a pair of molds having their face formed to represent stone, vent holes through the molds bored at their thinnest portions to prevent the formation of vacuum when the mold is withdrawn from the wall, rubber fins projecting forwardly beyond the operative surface of the molds to a sufficient distance to hold a sheet of waxed paper and to also retain a desired amount of stucco finish, sheet metal guards secured to the molds and holding the said rubber fins in place, a hinged connection for the molds on adjacent inner portions of the molds, and a fastening device on corresponding outer portions of the molds, the pin of the said fastening device being removable, and means for manually operating the molds.

3. In a mold for applying stucco on walls to represent stone, the combination of a pair of molds having their face formed to represent stone, rubber ns projecting forwardly beyond the operative surface of the molds to a sufiicient distance to hold a sheet of waxed paper and to also retain a desired amount of stucco finish, sheet metal guards secured to the molds and holding the said rubber fins in place, a hinged connection for the molds, said hinged connection including a hinge element on adjacent inner portions of the molds, and a fastening device on corresponding outer portions of the molds, the pin of the said fastening device being removable, and means for manually operating the molds. 4. In a mold for applying stucco on walls to represent stone, the combination of a pair of molds having their face formed to represent stone, vent holes through the molds bored at their thinnest portions to prevent the formation of vacuum when the molds are withdrawn from the wall, rubber fins projecting forwardly beyond the operative surface of the molds to a sufficient distance to hold a sheet of waxed paper and to also retain a desired amount of stucco finish, sheet metal guards secured'to the molds and holding the said rubber fins in place, a hinged connection for the molds, supports cast integral with the molds, and handles mounted on and held in fixed position by said supports.

5. A method of applying stucco on walls at right angles to each other to represent stone, consisting in applying a waxed paper sheet to molds having rubber walls and having their faces finished to represent stone', applying stuccofinish on said waxed paper to the extent to which the size of the molds will permit, then applying the stucco base coating to the walls, and thereafter applying the stucco finish carried by the rubber molds to the stucco base coating, and swinging the molds to a position at right angles to each other to apply the stucco finish to walls at right angles to each other.

6. In a mold for applying stucco on walls to represent stone, the combination of a pair of molds having their face formed to represent stone, vent holes through the molds bored at their thinnest portions to prevent the formation of vacuums when the mold is withdrawn from the wall, rubber fins projecting forwardly beyond the operative surface of the molds to a sufficient distance to hold a sheet of waxed paper and to also retain a desired amount of stucco finish, sheet metal guards secured to the molds and holding the said rubber fins in place, a hinged connection for the molds, supports cast integral with the molds, handles secured to said supports, the supports each having a longitudinal rib to engage the handles to anchor them against turning, the handles being recessed to receive said ribs.

7. A method of applying stucco on walls to represent stone, consisting in applying waxed paper to molds having flexible and resilient walls and having their faces finished to represent stone, applying stucco finish on said waxed paper in the molds to the extent to whichA the size of the molds will permit, thereafter applying the stucco to the wall directly from the mold, and vibrating the molds to remove them from the wall and leave the molded stucco applied to the Wall.

8. A method of applying stucco on walls to represent stone, consisting in applying waxed paper as a lining to a mold having flexible and resilient walls, applying a coat of stucco to the walls, applying additional stucco finish from the mold to the wall, removing the mold from the wall by vibrating same, and successively continuing the application of the mold with additional quantities of stucco finish.

9. A mold for applying stucco to a wall comprising a rigid body having yielding edge strips extending beyond and surrounding the body face, to conflnegl definite thickness of stucco in said mold and to permit the mold to be bodily vibrated, whereby to pack and adhesively apply the stucco to the wall.

DOUGLAS S. FRALICK. 

